There are limits to what FileMaker can do here and I think you've reached them. You might investigate setting up a mail merge from MS Word that uses data from FileMaker. The merge format for export records was originally designed so that you could export from word and then import into MS Word in order to do a Mail Merge.
A few posts here suggest it might even be possible to set this up with MS Word without doing the export and import but this isn't a feature of MS Word that I've tried to use so you'd have to research the help files in MS Word to see if this is possible and if so, how you would do it.
Thank you, at least this made me laugh! This beast of a database is my best friend and worst enemy. I doubt I'll have time to figure out doing mail merges with the volume I print out here until we stop using FM, but, at least now I know. Thanks!
"2) Is there a way to prevent email addressses and web addresses from being split onto two lines?"
From menu: File >> File options...>> Text uncheck the box: "Use Asian language line-breaking"
Thank you! That will solve at least one constant headache!